Fusion spliced fiber optic cable assemblies and breakout kits

ABSTRACT

The present disclosure describes fusion spliced cable assemblies. An assembly may include a first and a second fiber optic cable, where an end of at least a first optical fiber from the first fiber optic cable is fusion spliced together with an end of at least a second optical fiber from the second fiber optic cable, the first optical fiber having a first length of prepared fiber extending from the spliced end of the first optical fiber to a transition point of the first optical fiber, the second optical fiber having a second length of prepared fiber extending from the spliced end of the second optical fiber to a transition point of the second optical fiber, where the transition point of the first optical fiber is a distance from the transition point of the second optical fiber, and where a total length of prepared fiber is the sum of the first length of prepared fiber for the first optical fiber and the second length of prepared fiber for the second optical fiber; a support configured to engage at least a portion of the total length of prepared fiber such that the distance between the transition points of each optical fiber is less than the total length of prepared fiber of the first and second optical fibers; and a transition housing coupled to the first and second fiber optic cables and surrounding the support. Fusion spliced cable assembly breakout kits are also provided.

RELATED APPLICATION(S)

The present application claims priority from and the benefit of U.S.Provisional Patent Application Ser. No. 62/821,569, filed Mar. 21, 2019,the disclosure of which is hereby incorporated herein in its entirety.

FIELD

The present application is directed generally toward fusion splicedcable assemblies, and more particularly fusion spliced cable assembliesand breakout kits for optical cables.

BACKGROUND

It is common practice to fusion splice optical fibers in the field or ina factory to connect two or more cables or pieces of equipment together.Currently, after the optical fibers are spliced together, large splicetrays, enclosure boxes or long rigid tubes are used to protect thespliced optical fibers (see, e.g., tube 10 in FIG. 1 ). However, theseprotective enclosures may occupy considerable space and can restrict theflexibility of the cables or pieces of equipment being spliced together.

SUMMARY

A first aspect of the present invention is directed to a fusion splicedcable assembly. The assembly may include a first and a second fiberoptic cable, where an end of at least a first optical fiber from thefirst fiber optic cable is fusion spliced together with an end of atleast a second optical fiber from the second fiber optic cable. Thefirst optical fiber has a first length of prepared fiber extending fromthe spliced end of the first optical fiber to a transition point of thefirst optical fiber and the second optical fiber has a second length ofprepared fiber extending from the spliced end of the second opticalfiber to a transition point of the second optical fiber. The transitionpoint of the first optical fiber is a distance from the transition pointof the second optical fiber and a total length of prepared fiber isequal to the sum of the first length of prepared fiber for the firstoptical fiber and the second length of prepared fiber for the secondoptical fiber. The assembly may further include a support configured toengage at least a portion of the total length of prepared fiber suchthat the distance between the transition points of each optical fiber isless than the total length of prepared fiber of the first and secondoptical fibers and a transition housing coupled to the first and secondfiber optic cables and surrounding the support.

Another aspect of the present invention is directed to a fusion splicedcable assembly. The assembly may include a first and a second fiberoptic cable, where an end of at least a first optical fiber from thefirst fiber optic cable is fusion spliced together with an end of atleast a second optical fiber from the second fiber optic cable. Thefirst optical fiber has a first length of prepared fiber extending fromthe spliced end of the first optical fiber to a transition point of thefirst optical fiber and the second optical fiber has a second length ofprepared fiber extending from the spliced end of the second opticalfiber to a transition point of the second optical fiber. The transitionpoint of the first optical fiber is a distance from the transition pointof the second optical fiber, and a total length of prepared fiber isequal to the sum of the first length of prepared fiber for the firstoptical fiber and the second length of prepared fiber for the secondoptical fiber. The assembly may further include a support configured toengage at least a portion of the total length of prepared fiber suchthat the distance between the transition points of each optical fiber isless than the total length of prepared fiber of the first and secondoptical fibers. The support may include pre-formed grooves configured toreceive and secure at least a portion of the total length of preparedfiber in a folded condition within the support. The assembly may furtherinclude a transition housing coupled to the first and second fiber opticcables and surrounding the support.

Another aspect of the present invention is directed to a fusion splicedcable assembly. The assembly may include a first and a second fiberoptic cable, where an end of at least a first optical fiber from thefirst fiber optic cable is fusion spliced together with an end of atleast a second optical fiber from the second fiber optic cable. Thefirst optical fiber has a first length of prepared fiber extending fromthe spliced end of the first optical fiber to a transition point of thefirst optical fiber and the second optical fiber has a second length ofprepared fiber extending from the spliced end of the second opticalfiber to a transition point of the second optical fiber. The transitionpoint of the first optical fiber is a distance from the transition pointof the second optical fiber, and a total length of prepared fiber isequal to the sum of the first length of prepared fiber for the firstoptical fiber and the second length of prepared fiber for the secondoptical fiber. The support may include a generally cylindrical mandrelconfigured to engage at least a portion of the total length of preparedfiber. The engaged portion of the total length of prepared fiber iscoiled around the mandrel such that the distance between the transitionpoints of each optical fiber is less than the total length of preparedfiber of the first and second optical fibers. The assembly may furtherinclude a transition housing coupled to the first and second fiber opticcables and surrounding the support.

Another aspect of the present invention is directed to a fusion splicedcable assembly breakout kit. The breakout kit may include at least onefiber optic cable having at least a first optical fiber, the firstoptical fiber having a first length of prepared fiber. The breakout kitmay include a terminated cable assembly having at least a second opticalfiber, the second optical fiber having a second length of preparedfiber. A total length of prepared fiber is the sum of the first lengthof prepared fiber for the first optical fiber and the second length ofprepared fiber for the second optical fiber. The breakout kit mayinclude a fusion splice transition housing, where an end of the firstoptical fiber from the fiber optic cable is fusion spliced together withan end of the second optical fiber from the terminated cable assembly,the fusion spliced ends of the first and second optical fibers beingsecured within the fusion splice transition housing.

It is noted that aspects of the invention described with respect to oneembodiment, may be incorporated in a different embodiment although notspecifically described relative thereto. That is, all embodiments and/orfeatures of any embodiment can be combined in any way and/orcombination. Applicant reserves the right to change any originally filedclaim and/or file any new claim accordingly, including the right to beable to amend any originally filed claim to depend from and/orincorporate any feature of any other claim or claims although notoriginally claimed in that manner. These and other objects and/oraspects of the present invention are explained in detail in thespecification set forth below. Further features, advantages and detailsof the present invention will be appreciated by those of ordinary skillin the art from a reading of the figures and the detailed description ofthe preferred embodiments that follow, such description being merelyillustrative of the present invention.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a photograph of a prior art fusion splice optical fiberassembly having a long rigid tube protecting the fusion splice.

FIG. 2 is a side view of two optical fibers that have been fusionspliced together according to embodiments of the present invention.

FIGS. 3A-3C are exploded and assembled perspective views of a fusionspliced cable assembly according to embodiments of the presentinvention.

FIG. 4 is an exploded perspective view of another fusion spliced cableassembly according to embodiments of the present invention.

FIG. 5A is perspective view of an alternative mandrel that may be usedwith the fusion spliced cable assembly of FIG. 4 according toembodiments of the present invention.

FIG. 5B is a perspective view of two fusion spliced optical fiberswrapped around the mandrel of FIG. 5A according to embodiments of thepresent invention.

FIG. 6A is a side view of a fusion spliced cable assembly breakout kitaccording to embodiments of the present invention.

FIG. 6B is an exploded view of the fusion spliced cable assemblybreakout kit of FIG. 6A.

FIG. 6C is an enlarged view of the fusion spliced housing of the fusionspliced cable assembly breakout kit of FIGS. 6A-6B.

FIG. 6D is a side view of the furcation tubes and protective sleeve ofthe fusion spliced cable assembly breakout kit of FIG. 6A.

FIG. 6E is an enlarged perspective view of the furcation tubes andprotective sleeve shown in FIG. 6C.

FIG. 7 is a perspective view of another fusion spliced cable assemblybreakout kit according to embodiments of the present invention.

FIG. 8A is a perspective view of a ribbon fiber style furcation tube kitfor another fusion spliced cable assembly breakout kit according toembodiments of the present invention.

FIG. 8B is a perspective view of the ribbon fiber style furcation tubekit of FIG. 8A in combination with ribbonized fibers.

FIG. 8C is an exploded view of the fusion spliced cable assemblybreakout kit of FIGS. 8A-8B.

DETAILED DESCRIPTION

The present invention now is described more fully hereinafter withreference to the accompanying drawings, in which embodiments of theinvention are shown. This invention may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art.

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which illustrativeembodiments of the invention are shown.

In the figures, certain layers, components or features may beexaggerated for clarity, and broken lines illustrate optional featuresor operations unless specified otherwise. This invention may, however,be embodied in many different forms and should not be construed aslimited to the embodiments set forth herein; rather, these embodimentsare provided so that this disclosure will be thorough and complete, andwill fully convey the scope of the invention to those skilled in theart.

It will be understood that, although the terms first, second, etc. maybe used herein to describe various elements, components, regions, layersand/or sections, these elements, components, regions, layers and/orsections should not be limited by these terms. These terms are only usedto distinguish one element, component, region, layer or section fromanother region, layer or section. Thus, a first element, component,region, layer or section discussed below could be termed a secondelement, component, region, layer or section without departing from theteachings of the present invention. The sequence of operations (orsteps) is not limited to the order presented in the claims or figuresunless specifically indicated otherwise.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the specification andrelevant art and should not be interpreted in an idealized or overlyformal sense unless expressly so defined herein. Well-known functions orconstructions may not be described in detail for brevity and/or clarity.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising”, when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof. As used herein, the term “and/or”includes any and all combinations of one or more of the associatedlisted items.

As used herein, phrases such as “between X and Y” and “between about Xand Y” should be interpreted to include X and Y. As used herein, phrasessuch as “between about X and Y” mean “between about X and about Y.” Asused herein, phrases such as “from about X to Y” mean “from about X toabout Y.”

Pursuant to embodiments of the present invention, fusion spliced cableassemblies for optical fibers are provided that may eliminate the needto use long rigid enclosures to protect the spliced fibers byintegrating a ruggedized and compact transition area into the assembly.The fusion spliced cable assemblies of the present invention may be usedto house, organize and secure fusion spliced optical fibers. The fusionspliced cable assemblies of the present invention may reduce the spacebetween optical fibers that have been spliced together while maintainingthe minimum bend radius of the spliced fibers, and protect the splicearea from being damaged (e.g., bending and breaking). Embodiments of thepresent invention will now be discussed in greater detail with referenceto FIGS. 2-8C.

Fusion splicing is the process of fusing or welding two fibers togetherusually by an electric arc. The goal of fusion splicing is to fuse thetwo fibers end-to-end in such a way that light passing through thefibers is not scattered or reflected back by the splice, and so that thesplice and region surrounding the splice are almost as strong as theintact fibers. Before two fibers can be fusion spliced together, thefibers must be prepared.

Methods of preparing optical fibers for fusion splicing are well-knownand embodiments of the present invention are not limited to a specificmethod of preparation. Typically, preparation of the fibers may includethe fibers being (1) stripped, (2) cleaned, and (3) cleaved. First, anadequate amount of the protective coating, jacket, or cladding isremoved or stripped away from the ends of each optical fiber that willbe spliced together. Fiber optical stripping is usually carried out byusing a mechanical stripping device similar to a wire-stripper. Otherspecial stripping methods that utilize hot sulfuric acid or a controlledflow of hot air may be used to remove the coating. Next, the bare fibersshould be cleaned. The customary means to clean the fibers is withalcohol (e.g., isopropyl alcohol) and wipes. However, given thehydroscopic nature of isopropyl alcohol, its use is less desirable thanother known chemicals. Finally, each fiber is cleaved using thescore-and-break method so that the end-face of each fiber is perfectlyflat and perpendicular to the axis of the fiber. In fusion splicing,splice loss is a direct function of the angles and quality of the twofiber-end faces, i.e., the closer to 90 degrees the cleave angle, thelower the optical loss the splice will yield. As used herein, thesection of each optical fiber that has been prepared in this manner orin a similar manner will be referred to as “the prepared fibers.”

Referring to now FIGS. 2-4 , a fusion spliced cable assembly 100according to embodiments of the present invention is illustrated. Insome embodiments, a fusion spliced cable assembly 100 of the presentinvention may include a first fiber optic cable 102 a and a second fiberoptic cable 102 b. Each fiber optic cable 102 a, 102 b includes at leastone optical fiber 104 a, 104 b that will be fusion spliced together.FIG. 2 illustrates two optical fibers 104 a, 104 b that have been fusionspliced together at splice area 106. As shown in FIG. 2 , an end 105 aof the first optical fiber 104 a from the first fiber optic cable 102 ais spliced together with an end 105 b of the second optical fiber 104 bfrom the second fiber optic cable 102 b. In some embodiments, theoptical fibers 104 a, 104 b may comprise ribbonized optical fibers (see,e.g., FIGS. 8B-8C).

Before the ends 105 a, 105 b of the optical fibers 104 a, 104 b arespliced together, the optical fibers 104 a, 104 b are prepared asdiscussed above. After the optical fibers 104 a, 104 b have gone throughthe preparation process, the first optical fiber 104 a will have a firstlength (L_(P1)) of prepared fiber 104 a _(p) and the second opticalfiber 104 b will have a second length (L_(P2)) of prepared fiber 104 b_(p) (see, e.g., FIG. 2 ). The first length (L_(P1)) of prepared fiber104 a _(p) extends from the spliced end 105 a of the first optical fiber104 a to a transition point 103 a of the first optical fiber 104 a.Similarly, the second length (L_(P2)) of the prepared fiber 104 b _(p)extends from the spliced end 105 b of the second optical fiber 104 b toa transition point 103 b of the second optical fiber 104 b. Thus, thetotal length (L_(PT)) of prepared fiber 104 a _(p),104 b _(p) is equalto the sum of the first length (L_(P1)) of prepared fiber 104 a _(p) forthe first optical fiber 104 a and the second length (L_(P2)) of preparedfiber 104 b _(p) for the second optical fiber 104 b or(L_(P1))+(L_(P2))=(L_(PT)). In some embodiments, the length L_(P1),L_(P2) of each prepared fiber 104 a _(p), 104 b _(p) is in the range ofabout 60 mm to about 200 mm. In some embodiments, the total length(L_(PT)) of prepared fiber 104 a _(p), 104 b _(p) is in the range ofabout 70 mm to about 500 mm.

Note that each transition point 103 a, 103 b represents the point alonga longitudinal axis (A) of the respective optical fiber 104 a, 104 bwhere the protective coating (or cladding) of the optical fiber 104 a,104 b has not been removed or stripped away. In other words, thetransition point 103 a, 103 represents the point along the optical fiber104 a, 104 b where the fibers 104 a, 104 b “transition” from a preparedfiber 104 a _(p), 104 b _(p) to an unprepared fiber 104 a _(up), 104 b_(up).

Still referring to FIG. 2 , after the ends 105 a, 105 b of the opticalfibers 104 a, 104 b have been fusion spliced together, the transitionpoint 103 a of the first optical fiber 104 a is a first distance (D₁)from the transition point 103 b of the second optical fiber 104 b.Typically, at this time, the distance (D₁) between the transition points103 a, 103 b is approximately equal to the total length (L_(PT)) of theprepared fibers 104 a _(p), 104 b _(p). In some embodiments, thedistance (D₁) between the transition points 103 a, 103 b of the opticalfibers 104 a, 104 b is in a range of about 120 mm and about 500 mm. Atthis point in the process, prior known fusion spliced cable assemblieswould encapsulate the splice area 106 and the prepared fibers 104 a_(p), 104 b _(p) with a long sleeve or enclosure (e.g., tube 10 in FIG.1 ) that spans the entire distance (D₁) between the transition points103 a, 103 b of the optical fibers 104 a, 104 b. As discussed above,these long protective sleeves can occupy considerable space and canrestrict the flexibility of the optical fibers being spliced together.These shortcomings can be addressed via cable assembly embodimentsdescribed below.

Referring now to FIGS. 3A-3C, in some embodiments, the fusion splicedcable assembly 100 of the present invention may include a support 108.The support 108 may be configured to engage at least a portion of thetotal length (L_(PT)) of the prepared fibers 104 a _(p), 104 b _(p). Asshown in FIGS. 3A-3B, after the prepared fibers 104 a _(p), 104 b _(p)have been spliced together, the prepared fibers 104 a _(p), 104 b _(p)may be bent or folded to engage the support 108. In some embodiments, atleast a portion of the first length (L_(P1)) of the prepared fiber 104 a_(p) of the first optical fiber 104 a and/or at least a portion of thesecond length (L_(P2)) of the prepared fiber 104 b _(p) of the secondoptical fiber 104 b is substantially perpendicular to the longitudinalaxis (A) of the first and/or second optical fiber 104 a, 104 b. In someembodiments, at least two portions of the first length (L_(P1)) of theprepared fiber 104 a _(p) of the first optical fiber 104 a and/or thesecond length (L_(P2)) of prepared fiber 104 b _(p) of the secondoptical fiber 104 b are substantially perpendicular to a longitudinalaxis (A) of the first and/or second optical fiber 104 a, 104 b.

In some embodiments, the support 108 may comprise pre-formed grooves 108g. The grooves 108 g may be configured to receive and secure at least aportion of the total length (L_(PT)) of the prepared fibers 104 a _(p),104 b _(p) in a bent or folded condition within the support 108 (see,e.g., FIG. 3B). In some embodiments, the total length (L_(PT)) of theprepared fibers 104 a _(p), 104 b _(p) may be engaged with the support108 such that the edges of the support 108 are adjacent to or in contactwith the transition points 103 a, 103 b of the optical fibers 104 a, 104b (see, e.g., FIG. 3B).

In order to allow the prepared fibers 104 a _(p), 104 b _(p) to be bentor folded to engage the support 108, high bend-insensitive opticalfibers 104 a, 104 b having a small bend radius may be used. Utilizingoptical fibers 104 a, 104 b having a small or compact bend radius allowsthe prepared fibers 104 a _(p), 104 b _(p) to be bent or folded toengage the support 108 without high optical loss or risk of damaging theoptical fibers 104 a, 104 b. In some embodiments, the optical fibers 104a, 104 b may have a bend radius in the range of about 2.5 mm to about7.5 mm. For example, in some embodiments, the optical fibers 104 a, 104b may have a bend radius of 2.5 mm, 5 mm, or 7.5 mm.

Bending or folding the prepared fibers 104 a _(p), 104 b _(p) to engagethe support 108 allows the transition points 103 a, 103 b of eachoptical fiber 104 a, 104 b to be drawn closer to each other. Thisresults in a smaller or more compact transition area for the fusionspliced optical fibers 104 a, 104 b (i.e., the distance (D) between thetransition points 103 a, 103 b). For example, in some embodiments, thesupport 108 may be configured to engage the prepared fibers 104 a _(p),104 b _(p) such that a second distance (D₂) between the transitionpoints 103 a, 103 b of each optical fiber 104 a, 104 b is less than thetotal length (L_(PT)) of the prepared fibers 104 a _(p), 104 b _(p)(i.e., D₂<D_(r)).

As shown in FIGS. 3A-3B, in some embodiments, the support 108 may berectangular in shape having a length (L_(S)) and a width (W_(S)). Insome embodiments, support 108 may have a length (L_(S)) in the range ofabout 40 mm to about 80 mm and a width (W_(S)) in the range of about 10mm to about 40 mm. In some embodiments, the length (L_(S)) of thesupport 108 is approximately equal to the second distance (D₂) betweenthe transition points 103 a, 103 b of the optical fibers 104 a, 104 b.The support 108 of the present invention may be formed in a variety ofdifferent shapes, such as, for example, cylindrical (see, e.g., FIG.4A), prismatic, square or elliptical.

In some embodiments, the fusion spliced cable assembly 100 may include atransition housing 110. As shown in FIG. 3C, the transition housing 110has a length (L_(TH)) and may be coupled to the first and second fiberoptic cables 102 a, 102 b. In some embodiments, the transition housing110 may have a length (L_(TH)) in the range of about 40 mm to about 200mm. In some embodiments, the transition housing 110 may be cylindricalin shape. However, the transition housing 110 of the present inventionmay be formed in a variety of different shapes, such as, for example,rectangular or square.

After the prepared fibers 104 a _(p), 104 b _(p) have been engaged withthe support 108, the transition housing 110 may be slid over andsurround the support 108 to protect and/or further secure support 108and the spliced together prepared fibers 104 a _(p), 104 b _(p). In someembodiments, the transition housing 110 has a sufficient length (L_(TH))such that each transition point 103 a, 103 b is within the transitionhousing 110 (i.e., the length (L_(TH)) of the transition housing isgreater than the second distance (D₂) between the transition points 103a, 103 b). In some embodiments, an adhesive heat shrink tube or anover-molding may be used to encapsulate the transition housing 110 andfurther seal/protect the support 108 and spliced fibers 104 a, 104 bfrom, for example, moisture and UV light. In some embodiments, thetransition housing 110 may comprise thermal expansion/contractioncompensation features (or flexible material) to protect the splicedoptical fibers 104 a, 104 b from experiencing any strain and/or stressin any environmental condition.

In some embodiments, the transition housing 110 may comprise one or moreslots 114. The slots 114 may extend along the length (L_(TH)) of one ormore interior walls 110 w of the transition housing 110. In someembodiments, the slots 114 may be configured to receive and secure thesupport 108 within the transition housing 110. In some embodiments, thetransition housing 110 may be filled with a material to further seal andprotect the support 108 and fusion spliced optical fibers 104 a, 104 bwithin the transition housing 110. For example, in some embodiments, thetransition housing 110 may be filled with an optical adhesive or apotting compound.

In some embodiments, the fusion spliced cable assembly 100 of thepresent invention may further comprise a fusion splice protection tube112. The fusion splice protection tube 112 surrounds the spliced ends105 a, 105 b of the first and second optical fibers 104 a, 104 b and mayhelp to protect the splice area 106 from being damaged (e.g., bendingand breaking). In some embodiments, the fusion splice protection tube112 may be secured inside or outside of the transition housing 110.

Another fusion spliced cable assembly 200 according to embodiments ofthe present invention is illustrated in FIG. 4 . As shown in FIG. 4 , insome embodiments, the support 208 may comprise a mandrel 216. In someembodiments, the mandrel 216 may be generally cylindrical in shape. Insome embodiments, at least a portion of the total length (L_(PT)) of theprepared fibers 204 a _(p), 204 b _(p) may be coiled around the mandrel216. In some embodiments, after the prepared fibers 204 a _(p), 204 b_(p) have been coiled around the mandrel 216 of the support 208, themandrel 216 may be removed. In some embodiments, the mandrel 216 may beremoved prior to the transition housing 210 being slid over the splicedoptical fibers 204 a, 204 b. In some embodiments, at least a portion ofthe prepared fibers 204 a _(p), 204 b _(p) may be engaged and secured ina coiled condition with the support 208. In some embodiments,filament-type pre-impregnated composite fibers (“pre-preg”) may be usedto secure or coil the prepared fibers 204 a _(p), 204 b _(p) to thesupport 208.

Referring now to FIGS. 5A-5B, in some embodiments, the support 208 ofthe fusion spliced cable assembly 200 of the present invention maycomprise an alternative mandrel 216′. As shown in FIG. 5A, in someembodiments, the mandrel 216′ may comprise a base member 207 having alength (l), a width (w), and a thickness (t). In some embodiments, thebase member 207 may have a length (l) in the range of about 10 mm toabout 50 mm, a width (w) in the range of about 0 mm (i.e., no hole) toabout 20 mm, and a thickness (t) in the range of about 1 mm to about 10mm. The mandrel 216′ may further comprise two end members 209, each endmember 209 having a diameter (d) and a width (w) (the width (w) of theend members 209 being equal to the width (w) of the base member 207).Each end member 209 resides on an opposite end of the base member 207and may be coupled to or integral with the base member 207. In someembodiments, the end members 209 may have a generally cylindrical shape.For example, in some embodiments, each end member 209 may have adiameter (d) in the range of 10 mm to about 40 mm. The end members 209may be hollow or solid.

Similar to the cylindrical mandrel 216 discussed above, the mandrel 216′may be configured to engage at least a portion of the total length(L_(PT)) of the prepared fibers 204 a _(p), 204 b _(p). For example, asshown in FIG. 5B, in some embodiments, at least a portion of the totallength (L_(PT)) of the prepared fibers 204 a _(p), 204 b _(p) may bewrapped along the length (l) of the base member 207 and around each ofthe end members 209. In some embodiments, once the prepared fibers 204 a_(p), 204 b _(p) are wrapped around the mandrel 216′ of the support 208,the mandrel 216′ may be removed. In some embodiments, at least a portionof the prepared fibers 204 a _(p), 204 b _(p) is engaged and secured ina wrapped condition with the mandrel 216′ of the support 208.

Referring now to FIGS. 6A-6E, a fusion splice cable assembly breakoutkit 300 according to embodiments of the present invention isillustrated. In some embodiments, the breakout kit 300 may include atleast one fiber optic cable 302 having at least a first optical fiber304 b, the first optical fiber 304 a having a first length (L_(P1)) ofprepared fiber 304 a _(p) (similar to discussed above).

As shown in FIGS. 6A, 6D, and 6E, in some embodiments, the breakout kit300 may include a terminated cable assembly 315 and a plurality offurcation tubes 340. Each furcation tube 340 may have an inner tube 350which surrounds a plurality of optical fibers 304. As shown in FIG. 6B,the plurality of furcation tubes 340 extends outwardly from one end ofthe terminated cable assembly 315. In some embodiments, the furcationtubes 340 may comprise Kevlar® polymer.

In some embodiments, at least a second optical fiber 304 b of theplurality optical fibers 304 from the terminated cable assembly 315 isprepared to be fusion spliced together with the first optical fiber 304a of the fiber optic cable 302. The second optical fiber 304 b has asecond length (L_(P2)) of prepared fiber 304 b _(p). The prepared fibers304 a _(p), 304 b _(p) have a total length (L_(PT)) that is equal to thesum of the first length (L_(P1)) of prepared fiber 304 a _(p) for thefirst optical fiber 304 a and the second length (L_(P2)) of preparedfiber 304 b _(p) for the second optical fiber 304 b, i.e.,(L_(p1))+(L_(P2))=(L_(PT)). In some embodiments, an end of the firstoptical fiber 304 a from the fiber optic cable 302 is fusion splicedtogether with an end of the second optical fiber 304 b from theterminated cable assembly 315.

As shown in FIGS. 6B-6C, in some embodiments, the breakout kit 300 mayfurther include a fusion splice transition housing 310. The transitionhousing 310 is similar to embodiments described above. In someembodiments, the spliced ends of the first and second optical fibers 304a, 304 b are secured within the fusion splice transition housing 310.

As shown in FIGS. 6A-6B, the fusion splice cable assembly breakout kit300 may further include a protective sleeve 320 around the fusion splicetransition housing 310 and the terminated cable assembly 315. As shownin FIG. 6B, in some embodiments, the protective sleeve 320 may comprisea main body 320 b and a top 320 a. The top 320 a of the protectivesleeve 320 may be configured to be secured to the main body 320 b of theprotective sleeve 320. For example, in some embodiments, the top 320 aand the main body 320 b of the protective sleeve 320 b may each comprisethreads that are configured to cooperate with each other such that thetop 320 a may be screwed onto and secured to the main body 320 b. Asshown in FIG. 6B, the plurality of furcation tubes 340 extends throughone or more openings in the top 320 a of the protective sleeve 320. Insome embodiments, the furcation tubes 340 and/or inner tubes 350 may bebonded to the top 320 a of the protective sleeve (see, e.g., FIGS.6D-6E).

As shown in FIG. 6C, in some embodiments, the main body 320 b of theprotective sleeve 320 may comprise a slot 314. In some embodiments, theslot 314 may be configured to receive and secure the transition housing310 within the protective sleeve 320. In some embodiments, theprotective sleeve 320 may be filled with a material to seal and protectthe transition housing 310 and fusion spliced optical fibers 304 a, 304b within the transition housing 310. For example, in some embodiments,the protective sleeve 320 may be filled with an optical adhesive or apotting compound. In some embodiments, a heat shrink tube 330 (orover-molding) may be used where the furcation tubes 340 exit the top 320a of the protective sleeve 320. The heat shrink tube 330 may help tofurther seal and protect from moisture entering the protective sleeve320.

Referring now to FIG. 7 , the fusion splice cable assembly breakout kit300 of the present invention may further include an anti-rotationmechanism 322. As shown in FIG. 7 , the terminated cable assembly 315may comprise an anti-rotation key 322 a and the main body 320 b of theprotective sleeve 320 may comprise an anti-rotation notch 322 b. Theanti-rotation notch 322 b may be configured to receive and secure theanti-rotation key 322 a. When the anti-rotation key 322 a is secured inthe anti-rotation notch 322 b, the terminated cable assembly 315 isprevented from rotating within the protective sleeve 320, such as, forexample, when the top 320 a of the protective sleeve is being rotated(i.e., screwed) onto the main body 320 b of the protective sleeve 320.Preventing the terminated cable assembly 315 from rotating within theprotective sleeve 320 helps to further protect the optical fibers 304from being damaged.

Referring to FIGS. 8A-8C, another fusion splice cable assembly breakoutkit 300′ of the present invention is illustrated. The breakout kit 300′is similar to the fusion splice cable assembly breakout kit 300described above except the terminated cable assembly 315 is substitutedwith a ribbon fiber style furcation tube kit 315′. The fusion splicecable assembly breakout kit 300′ may be utilized when ribbonized opticalfibers 304 b are being fusion spliced together.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although exemplary embodiments of thisinvention have been described, those skilled in the art will readilyappreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention as defined inthe claims. The invention is defined by the following claims, withequivalents of the claims to be included therein.

That which is claimed is:
 1. A fusion spliced cable assembly, the assembly comprising: a first and a second fiber optic cable, wherein an end of at least a first optical fiber from the first fiber optic cable is fusion spliced together with an end of at least a second optical fiber from the second fiber optic cable, the first optical fiber having a first length of prepared fiber extending from the spliced end of the first optical fiber to a transition point of the first optical fiber, the second optical fiber having a second length of prepared fiber extending from the spliced end of the second optical fiber to a transition point of the second optical fiber, wherein the transition point of the first optical fiber is a distance from the transition point of the second optical fiber, and wherein a total length of prepared fiber is equal to the sum of the first length of prepared fiber for the first optical fiber and the second length of prepared fiber for the second optical fiber; a support configured to engage at least a portion of the total length of prepared fiber such that the distance between the transition points of each optical fiber is less than the total length of prepared fiber of the first and second optical fibers; and a transition housing coupled to the first and second fiber optic cables and surrounding the support, wherein an end of each fiber optic cable is sealed within the transition housing, wherein the transition housing comprises slots configured to receive and secure the support within the transition housing.
 2. The assembly of claim 1, wherein the support comprises pre-formed grooves configured to receive and secure at least a portion of the total length of prepared fiber in a folded condition within the support.
 3. The assembly of claim 1, wherein the support comprises a generally cylindrical mandrel, at least a portion of the total length of prepared fiber being coiled around the mandrel.
 4. The assembly of claim 1, wherein the first and second optical fibers have a minimum bend radius in the range of about 2.5 mm to about 7.5 mm.
 5. The assembly of claim 1, wherein the first and second optical fibers comprise ribbonized optical fibers.
 6. The assembly of claim 1, the assembly further comprising a fusion splice protection tube surrounding the spliced ends of the first and second optical fibers.
 7. The assembly of claim 6, wherein the fusion splice protection tube comprises an optical adhesive or potting compound.
 8. The assembly of claim 1, wherein the ends of each fiber optic cable are sealed within the transition housing by an adhesive heat shrink tube or over-molding.
 9. The assembly of claim 1, wherein at least a portion of the first length of the prepared fiber of the first optical fiber and at least a portion of the second length of the prepared fiber of the second optical fiber are over-molded or potted with a polymer or composite polymer.
 10. The assembly of claim 1, wherein at least a portion of the first length of the prepared fiber of the first optical fiber and at least a portion of the second length of the prepared fiber of the second optical fiber are secured to the support with filament-type pre-impregnated composite fibers.
 11. The assembly of claim 1, wherein the transition housing has a length in the range of about 40 mm to about 200 mm.
 12. The assembly of claim 1, wherein the total length of the prepared fiber is in the range of about 70 mm to about 500 mm.
 13. The assembly of claim 1, wherein the distance between the transition point of the first optical fiber and the transition point of the second optical fiber is in a range of about 120 mm to about 500 mm.
 14. The assembly of claim 1, wherein at least two portions of the first length of the prepared fiber of the first optical fiber and/or the second length of prepared fiber of the second optical fiber are substantially perpendicular to a longitudinal axis of the first and/or second optical fiber.
 15. A fusion spliced cable assembly, the assembly comprising: a first and a second fiber optic cable, wherein an end of at least a first optical fiber from the first fiber optic cable is fusion spliced together with an end of at least a second optical fiber from the second fiber optic cable, the first optical fiber having a first length of prepared fiber extending from the spliced end of the first optical fiber to a transition point of the first optical fiber, the second optical fiber having a second length of prepared fiber extending from the spliced end of the second optical fiber to a transition point of the second optical fiber, wherein the transition point of the first optical fiber is a distance from the transition point of the second optical fiber, and wherein a total length of prepared fiber is equal to the sum of the first length of prepared fiber for the first optical fiber and the second length of prepared fiber for the second optical fiber; a support configured to engage at least a portion of the total length of prepared fiber such that the distance between the transition points of each optical fiber is less than the total length of prepared fiber of the first and second optical fibers, the support comprising pre-formed grooves configured to receive and secure at least a portion of the total length of prepared fiber in a folded condition within the support; and a transition housing coupled to the first and second fiber optic cables and surrounding the support.
 16. A fusion spliced cable assembly, the assembly comprising: a first and a second fiber optic cable, wherein an end of at least a first optical fiber from the first fiber optic cable is fusion spliced together with an end of at least a second optical fiber from the second fiber optic cable, the first optical fiber having a first length of prepared fiber extending from the spliced end of the first optical fiber to a transition point of the first optical fiber, the second optical fiber having a second length of prepared fiber extending from the spliced end of the second optical fiber to a transition point of the second optical fiber, wherein the transition point of the first optical fiber is a distance from the transition point of the second optical fiber, and wherein a total length of prepared fiber is equal to the sum of the first length of prepared fiber for the first optical fiber and the second length of prepared fiber for the second optical fiber; a support comprising a generally cylindrical mandrel configured to engage at least a portion of the total length of prepared fiber, wherein the engaged portion of the total length of prepared fiber is coiled around the mandrel such that the distance between the transition points of each optical fiber is less than the total length of prepared fiber of the first and second optical fibers; and a transition housing coupled to the first and second fiber optic cables and surrounding the support.
 17. A fusion spliced cable assembly, the assembly comprising: a first and a second fiber optic cable, wherein an end of at least a first optical fiber from the first fiber optic cable is fusion spliced together with an end of at least a second optical fiber from the second fiber optic cable, the first optical fiber having a first length of prepared fiber extending from the spliced end of the first optical fiber to a transition point of the first optical fiber, the second optical fiber having a second length of prepared fiber extending from the spliced end of the second optical fiber to a transition point of the second optical fiber, wherein the transition point of the first optical fiber is a distance from the transition point of the second optical fiber, and wherein a total length of prepared fiber is equal to the sum of the first length of prepared fiber for the first optical fiber and the second length of prepared fiber for the second optical fiber; a support configured to engage at least a portion of the total length of prepared fiber such that the distance between the transition points of each optical fiber is less than the total length of prepared fiber of the first and second optical fibers; and a transition housing coupled to the first and second fiber optic cables and surrounding the support, wherein at least a portion of the first length of the prepared fiber of the first optical fiber and/or at least a portion of the second length of the prepared fiber of the second optical fiber is substantially perpendicular to a longitudinal axis of the first and/or second optical fiber. 